Product quality control analysis using integrated FMEA and TRIZ in metal stamping industry.

The metal stamping industry is an industry that is engaged in the metal stamping, anodizing and painting industries. The appearance of defective products or defects in the results of the spray painting process is, of course, detrimental to the industry because the industry has to repeat the production process, which causes additional production costs and material costs. The industry needs to find a way to reduce the number of defective products. This study used the failure mode and effect analysis (FMEA) method to analyze the problems. Based on research conducted on eight types of defects, the two defects that have the most significant percentage are dirty defects 32.07% and overpaint defects 27.04%. Based on the identification of the causes using FMEA, it is known that the dominant causative factors of the two types of defects are the operator's lack of discipline towards cleanliness SOPs and the operator's lack of consistency in a painting application. The recommendation for improvement based on the 40 Inventive Principles of TRIZ is to create a Personal Capability Status form in order to analyze what kind of work design errors have been done and then provide training to develop the talent of each operator and as an operator assessment so that they can provide rewards. This is done to improve performance so that disciplinary problems that impact product quality can be resolved. [ABSTRACT FROM AUTHOR]